Systems and methods for the fixation or fusion of bone

ABSTRACT

Various bone fixation/fusion devices are sized and configured to be placed across fracture fragments or between bones that are to be fused.

RELATED APPLICATIONS

This application is a divisional of co-pending U.S. patent application Ser. No. 11/653,504, which is a continuation-in-part of U.S. patent application Ser. No. 11/136,141, filed May 24, 2005, which is a continuation-in-part of U.S. patent application Ser. No. 10/914,629, filed Aug. 9, 2004 (now abandoned).

FIELD OF THE INVENTION

This application relates generally to the fixation of bone.

BACKGROUND OF THE INVENTION

Many types of hardware are available both for fracture fixation and for the fixation of bones that are to fused (arthrodesed).

Metal and absorbable screws are routinely used to fixate bone fractures and osteotomies. It is important to the successful outcome of the procedure that the screw is able to generate the compressive forces helpful in promoting bone healing.

SUMMARY OF THE INVENTION

The invention provides bone fixation/fusion devices and related methods for stabilizing bone segments, which can comprise parts of the same bone (e.g., fracture fixation) or two or more individual bones (e.g., fusion). The systems and methods include a fixation/fusion device adapted for placement in association with bone segments.

One aspect of the invention provides a bone fixation/fusion device comprising a body adapted for placement in association with a fracture line or between different bone segments, and at least one fixation ridge on the body.

In one embodiment, the fixation ridge includes a curvilinear portion.

In one embodiment, there are at least two spaced-apart fixation ridges on the body. In one arrangement, the separation distance between the fixation ridges remains essentially the same from one end of the fixation ridges toward an opposite end of the fixation ridges. In another arrangement, the separation distance between the fixation ridges changes from one end of the fixation ridges toward an opposite end of the fixation ridges.

In one embodiment there are a pair of cylindrical end caps on the body.

Another aspect of the invention provides a flexible bone fixation/fusion device.

In one embodiment, there are holes extending through the body. In one arrangement, the holes extend perpendicularly from the top to the bottom of the body. In another arrangement, the holes extend angularly from the top to the bottom of the body. In another arrangement, the holes extend perpendicularly from one side of the body to the other side of the body. In another arrangement, the holes extend angularly from one side of the body to the other side of the body.

In another embodiment, the body is formed with a hollow cavity.

In another embodiment, the body of the bone fixation/fusion device is formed in an accordion-type configuration.

Another aspect of the invention provides methods for placing a bone fixation/fusion device in bone.

One representative method provides a bone fixation/fusion device comprising a body and at least one fixation ridge on the body including a curvilinear portion. The method forms a bone cavity in a selected bone site including at least one slot in the bone cavity sized and configured to receive the fixation ridge. The method inserts the body in the bone cavity with the fixation ridge nesting within the slot.

In one embodiment, the selected bone site comprises a first bone segment, a second bone segment, and a non-bony region comprising an interruption between the first and second bone segments. In this embodiment, the representative method forms a first bone cavity in the first bone segment and a second bone cavity in the second bone segment across the interruption from the first bone cavity. The representative method forms in at least one of the first and second bone cavities at least one slot sized and configured to receive the fixation ridge. In this arrangement, the representative method inserts the body in the first bone cavity, the second bone cavity, and the interruption, with the fixation ridge nesting within the slot to apply compression between the first and second bone segments.

Another representative method provides a bone fixation/fusion device comprising a body and first and second spaced-apart fixation ridges on the body. The representative method forms a bone cavity in a selected bone site including first and second slots sized and configured to receive the first and second fixation ridges, respectively. In this arrangement, the representative method inserts the body in the bone cavity with the first and second fixation ridges nested within the first and second slots.

In one embodiment, the selected bone site comprises a first bone segment, a second bone segment, and a non-bony region comprising an interruption between the first and second bone segments. In this embodiment, the representative method forms a first bone cavity in the first bone segment including a first slot sized and configured to receive the first fixation ridge. The representative method also forms a second bone cavity in the second bone segment across the interruption from the first bone cavity, including forming a second slot sized and configured to receive the second fixation ridge. In this arrangement, the representative method inserts the body in the first bone cavity, the second bone cavity, and the interruption, with the first and second fixation ridges nesting within the first and second slots, respectively.

Another representative method provides a bone fixation/fusion device comprising a body and first and second fixation ridges on the body. The first and second fixation ridges are separated by a ridge separation distance. The representative method selects a bone site comprising a first bone segment, a second bone segment, and a non-bony region comprising an interruption between the first and second bone segments. The representative method forms a first bone cavity in the first bone segment including a first slot sized and configured to receive the first fixation ridge. The representative method forms a second bone cavity in the second bone segments across the interruption from the first bone cavity including a second slot sized and configured to receive the second fixation ridge. The first and second slots are separated by a slot separation distance that is greater than the ridge separation distance. In this arrangement, the representative method inserts the body in the first bone cavity, the second bone cavity, and the interruption with the first and second fixation ridges nesting within the first and second slots, respectively, to apply compression between the first and second bone segments.

In one embodiment, the selected bone sidte comprises a first done segment, a second bone segment, and a non-bony region comprising an interruption between the first and second bone segments. In this embodiment, the representative method forms a first bone cavity in the first bone segment including a first cylindrical aperture sized and configured to receive the first cylindrical end cap. The representative method forms a second bone cavity in the second bone segments across the interruption from the first bone cavity including a second cylindrical aperture sized and configured to receive the second cylindrical end cap. In this arrangement, the representative method inserts the body in the first bone cavity, the second bone cavity, and the interruption with the first and second end caps nesting within the first and second apertures, respectively.

Another representative method provides a bone fixation/fusion device comprising a body and first and second cylindrical end caps on the body. The center points of the first and second cylindrical end caps are separated by a end cap distance. The representative method selects a bone site comprising a first bone segment, a second bone segment, and a non-bony region comprising an interruption between the first and second bone segments. The representative method forms a first bone cavity in the first bone segment including a first cylindrical aperture sized and configured to receive the first cylindrical end cap. The representative method forms a second bone cavity in the second bone segments across the interruption from the first bone cavity including a second cylindrical aperture sized and configured to receive the second cylindrical end cap. The first and second slots are separated by a aperture separation distance that is greater than the end cap separation distance. In this arrangement, the representative method inserts the body in the first bone cavity, the second bone cavity, and the interruption with the first and second end caps nesting within the first and second apertures, respectively, to apply compression between the first and second bone segments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are perspective alternative views of a bone fixation/fusion device having a bony in-growth and/or through-growth region of a mesh configuration.

FIG. 2 is a perspective view of an alternative embodiment of a bone fixation/fusion device having a bony in-growth and/or through-growth region of a beaded configuration.

FIG. 3 is a perspective view of an alternative embodiment of a bone fixation/fusion device having a bony in-growth and/or through-growth region of a trabecular configuration.

FIG. 4 is a schematic view of a bone fixation/fusion device of the type shown in FIG. 1, being inserted in association with bone across a fracture line or between different bone segments.

FIG. 5 is a schematic view of a bone fixation/fusion device positioned in association with a fracture line or between different bone segments with a bony in-growth and/or through growth region extending across the fracture line or space between different bone segments.

FIG. 6 is a front plan view of an alternative embodiment of a bone fixation/fusion device having a bony in-growth and/or bony through-growth region, in which the device has a conical configuration.

FIG. 7 is front plan view of an alternative embodiment of a bone fixation/fusion device having a bony in-growth and/or through-growth region in which the device has a beveled distal tip.

FIGS. 8A and 8B are schematics illustrating the insertion of a bone fixation/fusion device of the type shown in FIG. 6 in association with a fracture line or between different bone segments.

FIG. 9 is a schematic illustrating a guidewire being introduced into bone in association with a fracture line or between different bone segments.

FIG. 10 is a schematic similar to FIG. 9 and illustrating a drill bit being introduced over the guidewire.

FIG. 11 is a schematic similar to FIG. 10 and illustrating a bore formed in the bone remaining after withdrawal of the drill bit.

FIG. 12 is a schematic similar to FIG. 11 and illustrating insertion of a bone fixation/fusion device into the pre-formed bore.

FIG. 13 is an exploded front plan view illustrating the coupling of a pair of bone fixation/fusion by threaded engagement.

FIG. 14 is a schematic illustrating a pair of bone fixation/fusion devices coupled together and inserted in association with a fracture line or between different bone segments.

FIG. 15 is a front plan view illustrating passage of a bone fixation/fusion device through a fenestration in another bone fixation/fusion device.

FIG. 16 is a schematic illustrating the placement of a series of bone fixation/fusion devices in bone.

FIG. 17 is a top plan view of a bone fixation/fusion device positioned in association with a fracture line or between different bone segments.

FIG. 18A is a perspective view of an alternative embodiment of a bone fixation/fusion device having a bony in-growth and/or bony through-growth region that extends substantially along the entire device.

FIG. 18B is a perspective view of a bone fixation/fusion device similar to FIG. 18A and having a bony in-growth and/or bony through-growth region that extends along a portion of the device.

FIG. 19 is a top plan view of the bone fixation/fusion device of FIG. 18A in positioned in association with a fracture line or between different bone segments.

FIG. 20 is a top plan view of the bone fixation/fusion device of FIG. 18A positioned in association with a fracture line or between different bone segments and stabilized by fixation screws.

FIGS. 21A to 21F are perspective views illustrating alternative configurations of bone fixation/fusion devices of a type shown in FIG. 18A.

FIGS. 22A and 22B are perspective views illustrating alternative embodiments of the bone fixation/fusion of a type shown in FIG. 18A in which the device is profiled.

FIGS. 23A and 23B are perspective views illustrating alternative embodiments of the bone fixation/fusion device of a type shown in FIG. 1 with structural elements that provide an anti-rotational function.

FIG. 24 is a perspective view illustrating an alternative embodiment of the bone fixation/fusion device of a type shown FIG. 18A in which the device includes a series of grooves providing an anti-rotational function.

FIG. 25 is a perspective view illustrating an alternative embodiment of the bone fixation/fusion device of a type shown in FIG. 18A in which the device includes a pair of opposing wings providing an anti-rotational function.

FIG. 26 is a perspective view illustrating an alternative embodiment of the bone fixation/fusion device of FIG. 18A in which the device includes a pair of opposing flanges providing an anti-rotational function.

FIG. 27 is an exploded view of a pair of coupled bone fixation/fusion devices that, when fitted together, form a composite bone fixation/fusion device.

FIG. 28 is an assembled view of the composite bone fixation/fusion device formed from the assembly of the bone fixation/fusion devices shown in FIG. 27.

FIG. 29 is a front view of the assembled composite bone fixation/fusion device of FIG. 28 positioned in association with a fracture line or between different bone segments.

FIG. 30 is a perspective view of an alternative embodiment of the bone fixation/fusion device of a type shown in FIG. 18A with fixation plates.

FIG. 31 is a perspective view of an alternative embodiment of the bone fixation/fusion device of FIG. 30.

FIG. 32 is a side view of an alternative embodiment of a fixation plate having a rounded configuration.

FIG. 33 is a side view of an alternative embodiment of a fixation plate having a tapered configuration.

FIG. 34 is a perspective view of an alternative embodiment of the bone fixation/fusion device of a type shown in FIG. 18A providing a series of radially-extending fixation ridges.

FIGS. 35A and 35B are perspective views of a bone fixation/fusion device having a malleable region that can be flared or expanded to provide fixation and/or anti-rotation resistance.

FIG. 36 is a front plan view illustrating the drilling of pilot holes in adjacent bone segments, which can comprise a fracture line in the same bone or different bone segments.

FIG. 37 is a front plan view illustrating a cavity bored between the pilot holes to receive a bone fixation/fusion device.

FIG. 38 is a front plan view illustrating the placement of a pair of guide pins within the bored cavity.

FIG. 39 is a front plan view illustrating the placement of the bone fixation/fusion device into the cavity and removal of the guide pins.

FIG. 40 is a front plan view illustrating the placement of a pair of opposing c-shaped restraints within the bored cavity.

FIG. 41 is a front plan view illustrating the placement of the bone fixation/fusion device into the cavity within the restraints.

FIG. 42 is a front plan view illustrating a bone cavity like that shown in FIG. 37 to receive a bone fixation/fusion device, the bone cavity in FIG. 42 showing the inclusion of slots to receive fixation ridges formed on the bone fixation/fusion device, as shown in FIG. 43.

FIG. 43 is a perspective view of a bone fixation/fusion device like that shown in FIG. 34 providing a series of radially-extending fixation ridges.

FIG. 44 is a front plan view showing placement of the bone fixation/fusion device shown in FIG. 43 in the slotted bone cavity shown in FIG. 42, with the distance between the bone slots being generally equal to the distance between the fixation ridges.

FIG. 45 is a front plan view showing placement of the bone fixation/fusion device shown in FIG. 43 in the slotted bone cavity shown in FIG. 42, with the distance between the bone slots being generally greater than the distance between the fixation ridges, to apply compression between adjacent bone segments.

FIG. 46 is a perspective view of a bone fixation/fusion device like that shown in FIG. 43 providing a series of radially-extending fixation ridges having curvilinear portions.

FIG. 47 is a top view showing placement of the bone fixation/fusion device shown in FIG. 46, with curvilinear ridges, in a slotted bone cavity like that shown in FIG. 42.

FIG. 48 is a perspective view of a bone fixation/fusion device like that shown in FIG. 46 providing a series of radially-extending fixation ridges having curvilinear portions.

FIG. 49 is a top view showing placement of the bone fixation/fusion device shown in FIG. 48, with curvilinear ridges, in a slotted bone cavity like that shown in FIG. 42.

FIG. 50 is a perspective view of a bone fixation/fusion device like that shown in FIG. 46 providing a series of radially-extending fixation ridges having curvilinear portions.

FIG. 51 is a side section view taken generally along line 51-51 in FIG. 50, showing a ridge portion with a generally vertical draft.

FIG. 52 is a side section view taken generally along line 52-52 in FIG. 50, showing a ridge portion with a more horizontal or angled draft, comprising a curvilinear ridge portion.

FIG. 53 is a top view showing placement of the bone fixation/fusion device shown in FIG. 50, with curvilinear ridges, in a slotted bone cavity like that shown in FIG. 42.

FIG. 54 is a superior anatomic view of a human foot, showing the placement of a bone fixation/fusion device of a type shown in FIG. 43 in a bone cavity in the first and second metatarsal bones, medial and middle cuneiform bones, and spanning the tarsometatarsal joint.

FIG. 55 is a medial side view of the human foot shown in FIG. 54.

FIG. 56 is a perspective view of a bone fixation/fusion device like that shown in FIG. 43 showing the flexibility of the bone fixation/fusion device about an axis A.

FIG. 57 is a perspective view of a bone fixation/fusion device like that shown in FIG. 43 showing the flexibility of the bone fixation/fusion device about an axis B.

FIG. 58 is a perspective view of a bone fixation/fusion device like that shown in FIG. 43 providing a plurality of holes extending perpendicularly through the bone fixation/fusion device from the top to the bottom.

FIG. 59 is a perspective view of a bone fixation/fusion device like that shown in FIG. 43 providing a plurality of holes extending angularly through the bone fixation/fusion device from the top to the bottom.

FIG. 60 is a perspective view of a bone fixation/fusion device like that shown in FIG. 43 providing a plurality of holes extending perpendicularly through the bone fixation/fusion device from one side to the other.

FIG. 61 is a perspective view of a bone fixation/fusion device like that shown in FIG. 43 providing a plurality of holes extending angularly through the bone fixation/fusion device from one side to the other.

FIG. 62 is a perspective view of a bone fixation/fusion device like that shown in FIG. 43 providing a hollow cavity within the bone fixation/fusion device.

FIG. 63 is a front plan view illustrating a bone cavity like that shown in FIG. 42 to receive a bone fixation/fusion device, the bone cavity in FIG. 63 showing the inclusion of cylindrical end apertures to receive the cylindrical end caps formed on the bone fixation/fusion device, as shown in FIG. 64.

FIG. 64 is a perspective view of a bone fixation/fusion device like that shown in FIG. 43 providing a pair of cylindrical end caps.

FIG. 65 is a front plan view showing placement of the bone fixation/fusion device shown in FIG. 64 in the cavity shown in FIG. 63, with the distance between the center points of the cylindrical end apertures being generally equal to the distance between center points of the cylindrical end caps.

FIG. 66 is a front plan view showing placement of the bone fixation/fusion device shown in FIG. 64 in the cavity shown in FIG. 63, with the distance between the center points of the cylindrical end apertures being generally greater than the distance between the center points of the cylindrical end caps, to appy compression between adjacent bone segments.

FIG. 67 is a perspective view of a bone fixation/fusion device like that shown in FIG. 43 providing a hollow cavity within the bone fixation/fusion device, and further including an accordian-like section to increase the flexibility of the device.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention that may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.

FIGS. 1A and 1B show representative alternative configurations of a device 10 sized and configured for the fixation of bone fractures (i.e., fixation of parts of the same bone) or for the fixation of bones which are to be fused (arthrodesed) (i.e. fixation of two or more individual bones that are adjacent and/or jointed). For the sake of shorthand, the device will sometimes be called a bone fixation/fusion device, to indicate that it can perform a fixation function between two or more individual bones), or a fusion function between two or more parts of the same bone, or both functions. As used herein, “bone segments” or “adjacent bone regions” refer to either situation, i.e., a fracture line in a single bone or a space between different bone segments.

In the embodiments shown in FIGS. 1A and 1B, the bone fixation/fusion device 10 comprises an elongated, stem-like structure. The device 10 can be formed—e.g., by machining, molding, or extrusion—from a material usable in the prosthetic arts, including, but not limited to, titanium, titanium alloys, tantalum, chrome cobalt, surgical steel, or any other total joint replacement metal and/or ceramic, sintered glass, artificial bone, any uncemented metal or ceramic surface, or a combination thereof. Alternatively, the device 10 may be formed from a suitable durable biologic material or a combination of metal and biologic material, such as a biocompatible bone-filling material. The device 10 may be molded from a flowable biologic material, e.g., acrylic bone cement, that is cured, e.g., by UV light, to a non-flowable or solid material.

The bone fixation/fusion device 10 can take various shapes and have various cross-sectional geometries. The device 10 can have, e.g., a generally curvilinear (i.e., round or oval) cross-section—as FIG. 1A shows—or a generally rectilinear cross section (i.e., square or rectangular or triangular—as FIG. 1B shows for purposes of illustration), or combinations thereof. As will be described in greater detail later (see, e.g., FIGS. 21A to 21F), instead of being shaped like an elongated stem, the body of the bone fixation/fusion device 10 can be less elongated and form more of a flattened, “wafer” configuration, having, e.g., a rectangular, square, or disc shape.

As FIGS. 2 and 3 show, the bone fixation/fusion device 10 desirably includes a region 12 formed along at least a portion of its length to promote bony in-growth onto or into surface of the device 10 and/or bony growth entirely through all or a portion of the device 10.

The region 12 can comprise, e.g., through holes, and/or various surface patterns, and/or various surface textures, and/or pores, or combinations thereof. The device 10 can be coated or wrapped or surfaced treated to provide the bony in-growth or through-growth region 12, or it can be formed from a material that itself inherently possesses a structure conducive to bony in-growth or through-growth, such as a porous mesh, hydroxyapetite, or other porous surface. The device 10 may further be covered with various other coatings such as antimicrobial, antithrombotic, and osteoinductive agents, or a combination thereof. The region 12 may be impregnated with such agents, if desired.

The configuration of the region 12 can, of course, vary. By way of examples, FIG. 1 shows the region 12 as an open mesh configuration; FIG. 2 shows the region 12 as beaded configuration; and FIG. 3 shows the region as a trabecular configuration. Any configuration conducive to bony in-growth and/or bony through-growth will suffice.

In use (see FIGS. 4 and 5), the bone fixation/fusion device 10 is inserted into a space between two adjacent bone surfaces, e.g., into a fracture site in a single bone or between two bones (e.g., adjacent vertebral bodies) which are to be fused together. In FIG. 4, the device 10 is shown being tapped into bone through bone segments 14 (i.e., across a fracture line or between adjacent bones to be fused) with a tap 16. The bone may be drilled first to facilitate insertion of the device 10. The bony in-growth or through-growth region 12 along the surface of the device 10 accelerates bony in-growth or through-growth onto, into, or through the device 10. Bony in-growth or through-growth onto, into, or through the device 10 helps speed up the fusion process or fracture healing time.

The bony in-growth or through-growth region 12 may extend along the entire outer surface of the device 10, as shown in FIG. 4, or the bony in-growth or through-growth region 12 may cover just a specified distance on either side of the bone segments or fracture line, as shown in FIG. 5.

The size and configuration of the device 10 can be varied to accommodate the type and location of the bone to be treated as well as individual anatomy.

As FIG. 6 shows, the device 10 can be angled or tapered in a conical configuration. The degree of angle can be varied to accommodate specific needs or individual anatomy. A lesser degree of angle (i.e., a more acute angle) decreases the risk of splitting the bone as the device 10 is tapped into the bone or the fracture segments 14. The device 10 may also include a beveled distal tip 18 to further add in insertion of the device 10 into bone, as shown in FIG. 7. As shown in FIGS. 8A and 8B, the conical shape also helps drive the bone segments or fracture fragments together, reducing the gap (G) between the bone segments 14 or fracture segments.

In FIGS. 9 to 12, the device 10 is cannulated, having a central lumen or throughbore 20 extending through it, to assist in the placement of the device 10 within bone. FIG. 1B also shows a cannulated throughbore 20 in a different configuration.

In use, the physician can insert a conventional guide pin 22 through the bone segments 14 by conventional methods, as FIG. 9 shows. A cannulated drill bit 24 can then be introduced over the guide pin 22, as seen in FIG. 10. A single drill bit or multiple drill bits 24 can be employed to drill through bone fragments or bone surfaces to create a bore 26 of the desired size and configuration. In the illustrated embodiment, the drill bit 24 is sized and configured to create a conical bore 26 similar in size and configuration to the device 10. The bore 26 is desirably sized and configured to permit tight engagement of the device 10 within the bore 26 and thereby restrict movement of the device 10 within the bore 26. The pre-formed bore 26 may be slightly smaller than the device 10, while still allowing the device 10 to be secured into position within the bore 26 by tapping. As seen in FIG. 11, the drill bit 24 is then withdrawn. The device 10 is then inserted into the bore 26 over the guide pin 22, as FIG. 12 shows. The guide pin 22 is then withdrawn.

Alternatively, the bone fixation/fusion device 10 itself can include screw-like threads along the body for screwing the device into place. In the arrangement, the device 10 be self-tapping. Also in this arrangement, the device 10 can be cannulated for use with a guide pin 22, or it need not be cannulated.

Multiple devices 10 may be employed to provide additional stabilization. While the use of multiple devices 10 will now be described illustrating the use of multiple devices 10 of the same size and configuration, it is contemplated that the devices 10 may also be of different size and/or configuration, e.g., one device 10 is of a cylindrical configuration and a second device 10 is of a conical configuration.

In many cases, it may be desirable to couple a series of devices 10 together, e.g., to provide stabilization over a larger surface area. A series of devices 10 may be coupled together be any suitable means, e.g., by a snap fit engagement, or a groove and tab key arrangement, or by a Morse taper fit, or combinations thereof. In one embodiment, a series of devices 10 are coupled by threaded engagement. As illustrated in FIG. 13, a first device 10A includes a recess 28 at one end providing a series of internal threads 30. In the illustrated embodiment, the first device 10 is of a cylindrical configuration, but may be of any desired configuration. The internal threads 30 couple with a series of complementary external threads 32 on a second device 10B of a similar or of a different configuration to couple the first and second devices 10A and 10B together.

The devices 10A and 10B are desirably coupled together prior to being inserted into the pre-formed bore 26. The series of internal and external threads 30 and 32 provide an interlocking mechanism that permits a series of devices 10 to be stacked and connected to cover a larger area or multiple bone segments 14 (e.g., a bone having multiple fractures) and thereby provides additional stabilization, as seen in FIG. 14.

FIG. 15 illustrates another embodiment in which a device 10′ includes an opening or fenestration 34 to allow another device 10 to pass through, thereby providing additional stabilization. The fenestration 34 can be sized and configured to permit another device 10 to be passed through the device 10′ at virtually any angle. The fenestration 34 can also be sized and configured to limit movement of the second device 10 relative to the second device 10′.

In use, and as shown in FIG. 16, the physician taps a first device 10′ having a fenestration 34 through the bone segments. A second device 10 is then inserted (e.g., by tapping) through the fenestration 34 of the first device 10′ into place.

It is further contemplated that device 10′ may also be adapted for coupling with another device 10A (e.g., by a series of external and internal threads), permitting the devices 10′ and 10A to be additionally stacked and connected, as also shown in FIG. 16.

FIG. 17 illustrates an alternative form of a bone fixation/fusion device 100. Similar to the type of bone fixation/fusion device 10 previously described, device 100 includes a body 106 formed of a durable material that is not subject to significant bio-absorption or resorption by surrounding bone or tissue over time. In other words, the body 106 is intended to remain in place for a time sufficient to stabilize the fracture or fusion site. Such materials are well know in the prosthetic arts and include, e.g., titanium, titanium alloys, tantalum, chrome cobalt, surgical steel, or any other total joint replacement metal and/or ceramic, sintered glass, artificial bone, any uncemented metal or ceramic surface, or a combination thereof. Alternatively, the body 106 of the bone fixation/fusion device 100 may be formed from a suitable durable biologic material or a combination of metal and biologic material, such as a biocompatible bone-filling material. The body 106 of the device 100 may be molded from a flowable biologic material, e.g., acrylic bone cement, that is cured, e.g., by UV light, to a non-flowable or solid material.

The body 106 of the device 100 may also include a bony in-growth or through-growth region 108, as already described in association with previous embodiments.

Unlike the bone fixation/fusion device 10, the bone fixation/fusion device 100 includes at least one region associated with the body 106 that, in contrast to the body 106, comprises a material that is subject to more rapid in vivo bio-absorption or resorption by surrounding bone or tissue over time, e.g., within weeks or a few months. The resorbable material can comprise, e.g., polylactic acid (PLA), polyglycolic acid (PGA), poly(lactideglycolide) copolymers, polyanliydrides, cyclode, cirsns, polyorthoasters, n-vinyl alcohol, or other biosorbable polymers or like materials known or recognized in the prosthetic arts as having such characteristics. The bio-absorbable region is intended to facilitate implantation or placement of the body 106, but over time be absorbed to minimize the footprint of the implanted device 100 in the long run.

The bioabsorbable region or regions can possess functionality to aid in the implantation process. For example, as shown the illustrated embodiment, there are two bioabsorbable regions 102 and 104. Region 102 comprises a bioabsorbable screw region 102, which is desirably threaded or otherwise suitably configured to pierce bone and facilitate advancement of the device 100 into bone. The other region 104 comprises a bioabsorbable head region 104, which is desirably configured to mate with an installation instrument, e.g., a screwdriver, to further facilitate advancement and positioning of the bone fixation/fusion device 100 in bone. The bioabsorbable head 104 may also be sized and configured to temporarily anchor the device 100 within bone, e.g., the head 104 may be a slightly larger diameter than the body 106 of the device 100. The bioabsorbable screw portion 102 and head portion 104 are configured to provide an immediate benefit during the initial placement or position of the device 100, but over time be resorbed when they have served their initial purpose during implantation. This leaves the more durable and less resorbable body 106 behind, to serve its longer-term function of stabilizing the fracture or fusion site.

As previously disclosed, a given bone fixation/fusion device can take various shapes and geometries. For example, as shown in FIGS. 18A and 18B, the bone fixation/fusion device 200 possesses a flattened rectangular (or wafer-like) configuration. A region 12 of the device 200 can be textured or treated, as previously described, to provide bony in-growth or through-growth. The bony in-growth or through-growth region 12 may extend along the entire device 200 (see FIG. 18A) or along any portion or portions of the device 200 (see FIG. 18B).

The bone fixation/fusion device 200 is desirably sized and configured to be positioned to join two or more adjacent bone segments 14 (which can comprise a fracture site, a fusion site, or both), as FIG. 19 shows, to fix and to promote the fusion of the adjacent bone segments 14. The device 200 may also be sized and configured to fix and to promote fusion of multiple bone segments 14 or compound fractures, as FIG. 20 shows. FIG. 20 illustrates placement of the bone fixation/fusion device 200 sized and configured for the fixation and fusion of, for example, a first cuneiform (CE1), a second cuneiform (CE2), a first metatarsal (M1), and a second metatarsal (M2).

As shown in FIG. 20, one or more auxiliary fixation elements, such as conventional orthopedic screws 206, may also be placed within and/or across the bone segments 14 by conventional techniques, to augment the stabilization of the bone segments 14 during the fusion process.

The size and configuration of the bone fixation/fusion device 200 may be modified or adjusted in diverse ways to serve the intended stabilization function in diverse bone locations, bone geometries, or bone types, which are intended to be fused or repaired. The bone fixation/fusion device 200 can come in a family of different pre-established sizes and shapes, or it can be individually sized and configured to meet the requirements of a particular individual's anatomy. For the sake of illustration, by not limitation, a given bone fixation/fusion device 200 may take the form of a disc (FIG. 21A), a square (FIG. 21B), or an oval (FIG. 21C). The height, width, and length of a given bone fixation/fusion device 200 may be varied depending on the specific location and amount of bone to be crossed for stabilization. A given bone fixation/fusion device may possess a symmetric geometry, or an asymmetric or complex geometry—such as an L shape (FIG. 21D), a triangle (FIG. 21E), or rectangle with a triangular ends (FIG. 22F). Any combination of linear or curvilinear or rounded geometries is possible.

As before described, a given bone fixation/fusion device can be cannulated to aid in guidance during placement or implantation. For example, as shown in FIGS. 18A and 18B, the device 200 can include a pair of opposing guide bores 202. The guide bores 202 are sized and configured to accommodate passage of guide pins 204, which are secured at the intended site of device placement. Other forms of cannulated devices 200 are shown in FIGS. 21B and 24. In this way, the bone fixation/fusion device 200 can be guided by the pins 204 to the intended bone placement site.

To aid in stabilizing a given bone fixation/fusion device within bone, the device may be profiled. For example, as shown in FIG. 22A, the bone fixation/fusion device 200 may vary in height across its entire length of the device 200, to form a tapered wedge. Alternatively, as shown in FIG. 22B, the bone fixation/fusion device 200 may vary in height at one end only. In these arrangements, the bone fixation/fusion device 200 is desirably positioned with the area of greatest height in the proximal direction, which serves to wedge the device 200 into place within bone.

To also aid in stabilizing a given bone fixation/fusion device within bone, the device can include one or more anti-rotational elements, which further stabilize and secure the device in the desired position within bone. The size and configuration of the anti-rotational elements may vary. For example, the anti-rotational elements may comprise an array of fins 300 projecting from a stem-like device 10 (FIG. 23A), or an array of grooves 302 formed in a rectangular wafer device 200 (FIG. 24), or wings 304 formed in a rectangular wafer device 200 (FIG. 25), or flanges 306 projecting from a wafer device 200 (FIG. 26). The anti-rotational elements can comprise (see FIG. 23B) an array of bumps 308 or surface projections 310 formed on all or a portion of the device, which can be either stem-like or wafer-like in its configuration. Any number of anti-rotational elements, or any configuration of anti-rotational elements, or any combinations of configurations can be provided to serve the functional objective of stabilization.

As also previously described, two or more bone fixation/fusion devices 200 of the types generally described above may be assembled to form a composite bone fixation/fusion device having a desired size and configuration. For example, in the arrangement shown in FIGS. 27 to 29, the bodies of two bone fixation/fusion devices 200 each have a slot 208. Slot 208 in a first device 200 mates with a like or complementary slot 208 in a second device 200 to permit the assembly of a composite bone fixation/fusion device 310, which has a crossed, anti-rotational configuration for placement across bone segments 14. The crossed relation of the composite bone fixation/fusion device 310 has an increased surface area and adds further stability to the devices 200 in bone during the fusion process.

It will be apparent to one of skill in the art that the location, size, and configuration of the slots 208 may be varied to accommodate specific needs and a specific anatomical location as well as individual anatomy. It is also apparent that other mating configurations, e.g., groove and tab fitments, or snap-fit arrangements, or Morse taper fits, or threaded assemblies, can be use to assemble two or more bone fixation/fusion devices into a composite device 310.

As shown in FIG. 30, fixation or gripping plates 212 may be fitted to a given bone fixation/fusion device. In the arrangement shown in FIG. 30, the body of the bone fixation/fusion device 200 includes one or more attachment sites 210, e.g., slits or indentations, which are sized and configured to receive a selectively removable fixation or gripping plate 212. When received within the slit 210, the plate 212 extends radially from the device to grip into bone and further secure the device 200 within bone.

In an alternative embodiment, shown in FIG. 31, the attachment site 210 can include a tab 214, which mates with a notch 216 in the fixation plate 212 to secure the plate 212 within the device 200.

Other forms of interlocking or nesting configuration can be used. For example, tongue-and-groove fitments, or snap-fit arrangements, or threaded fitments, or Morse taper assemblies can be use to assemble one or more fixation or gripping plates to a bone fixation/fusion device.

The fixation or gripping plate 212 is formed of durable biocompatible metal or bone substitute material, as previously described. In some cases, it may be desirable to provide a bony in-growth surface on at least a portion of the plate 212. Alternatively, the plate 212 may be formed of a bio-absorbable material, as already described.

FIGS. 30 and 31 illustrate embodiments in which the plates 212 present a generally blunt and flat configuration. It will be apparent to one of skill in the art that, however, that the plates 212 may also provide a sharpened or cutting edge or be otherwise sized and configured as necessary to accommodate specific location and individual anatomy. For example, the plate 212 may be rounded (FIG. 32) or tapered (FIG. 33).

FIG. 34 illustrates an alternative embodiment in which one or more fixation ridges 218 extend radially from the bone fixation/fusion device 200. Similar to the fixation plates 212, the ridges 218 may be variously sized and configured so as to grip into bone and further secure the bone fixation/fusion device 200 within bone.

Fixation elements can be formed in situ. For example, as shown in FIG. 35A, a bone fixation/fusion device 200 can include a malleable region 320 that normally presents a low-profile conducive to implantation. As FIG. 35B shows, the profile of the malleable region 320 can be changed in situ after implantation to a radially enlarged or extended profile 326 that provides stabilization or an anti-rotational function to the device 200. In the illustrated embodiment, the malleable region 320 is slotted (see FIG. 35A) to accommodate placement of a wedge tool 324 carried for manipulation by a stylet or cannula 322 (see FIG. 35B). The wedge tool 324 flays apart the slotted malleable region 320 (as FIG. 35B shows), to create the enlarged profile 326 for stabilization and/or rotation resistance.

In use, and with reference to FIG. 36, pilot holes 220 are drilled into adjacent bone segments 14 (e.g., along a fracture line in a single bone or between adjacent segments of different bones) by conventional surgical techniques. In the illustrated embodiment, a single pilot hole 220 is drilled into each bone segment 14. It is to be understood that the number and configuration of the pilot holes 220 may vary as necessary or as desired.

As shown in FIG. 37, the physician can then then saw, using conventional methods, between the pilot holes 220 to prepare a cavity 222 to receive the device 200.

Guide pins 204 may, if desired, be placed at opposing ends of the bored cavity 222, as seen in FIG. 38. In this arrangement, as shown in FIG. 39, the selected bone fixation/fusion device 200 is passed over the guide pins 204 to position the device 200 with the cavity 222. The guide pins 204 may then be removed. In an alternative arrangement, guide pins 204 need not be used, and the device 200 is manually inserted by the physician into the bore cavity 222.

An alternative embodiment is illustrated in FIGS. 40 and 41. In this embodiment, a c-shaped restraint 224 is placed against each end of the bored cavity 222. The selected bone fixation/fusion device 200 is then positioned between the restraints 222 such that the restraints 222 engage the device 200 to secure the device 200 within bone.

When the bone fixation/fusion device 200 includes one or more fixation ridges or fins 218 (as shown in FIG. 34 and again in FIG. 43), slots 230 can be sawed or cut within the bored cavity 222 using conventional tools, as FIG. 42 shows. The slots 230 are sized and configured so that the ridges 218 nest with the slots 230, to fixate the ridges 218 and thus the fixation/fusion device 200 within and between the adjacent bone segments 14. The nesting relationship between the ridges 218 and the slots 230 put the adjacent bone segments into compression, at least resisting further enlargement of the distance between them.

As FIG. 42 shows, the slots 230 are formed in a spaced-apart relationship within the respective bone segments 14, at a distance designated D_(S) in FIG. 42. The distance D_(S) takes into account the distance between the fixation ridges of the device 200, designated D_(F) in FIG. 42. Desirably, D_(F) is at least generally equal to and is not substantially greater than D_(S). In this way, the distance between the adjacent bone segments 14, designated G₁ in FIG. 42 (which can comprise a fracture line in a single bone or a gap between adjacent segments of different bone), is not enlarged by the presence of the device 200. This outcome is shown in FIG. 44, where D_(F) is generally equal to D_(S). As FIGS. 42 and 44 show, the interval G₁ between the adjacent bone segments 14 before installation of the device 200 (FIG. 42) is generally the same after installation of the device 200 (FIG. 44).

In certain instances, it may be desirable to make the distance D_(S) between the slots 230 slightly larger (e.g., from about at least 0.5 mm to about 3 mm farther apart) than the distance D_(F) between the ridges 218. This arrangement is shown in FIG. 45. In this arrangement, when the device 200 is introduced, the ridges 218 serve to pull the adjacent bone segments closer together, while also applying compression to maintain this condition (as shown by arrows in FIG. 45). As FIGS. 42 and 45 show, the interval G₂ between the adjacent bone segments 14 after installation of the device 200 (FIG. 45) is smaller than the interval G₁ before installation of the device 200 (FIG. 42).

The ridges 218 shown in the preceding embodiments (see, e.g., FIGS. 34 and 43) are generally uniformly linear in configuration. As shown in FIG. 46, the ridges 218 can be non-uniform and curvilinear in configuration, meaning that the ridges 218 can include portions that curve or are otherwise not uniformly straight. The curvilinear configuration can vary.

FIG. 46 shows, as one representative embodiment, curvilinear ridges 218, each of which includes generally linear end portions 232 and a curved, non-linear (curvilinear) intermediate portion 234. The distance R₁ between the linear end portions 232 is greater than the distance R₂ between the curved intermediate portion 234. As FIG. 46 shows, the curved portions 234 generally face inward toward the centerline of the device 200 in a symmetric fashion. It should be appreciated, that an asymmetric arrangement between the linear and curved portions 232 and 234 among the ridges 218 can be used.

In use, as FIG. 47 shows, the curvilinear ridges 218 nest within the formed slots 230, which can themselves be more easily formed in bone in a linear fashion. Within the linear slots 230, the undulating curved portions 234 of the curvilinear ridges 218 abut against or otherwise extend closer to the walls the formed linear slots 234 than the linear portions 232. The presence of curvilinear ridges 218 reduces or prevents “play” or lateral shifting of the device 200 within the bone cavity 222 after being placed in adjacent bone segments 14. The curvilinear ridges 218 stabilize or fixate placement of the device 200 within the bone cavity 222, accommodating differences in dimensional tolerances that may exist between the ridges 218 on the device 200 and slots 230 formed in the bone cavity 222. The curvilinear ridges 218 also serve to augment compression (shown by arrows in FIG. 47) between the adjacent bone segments 14, to establish and maintain a desired relationship between them for fusion or fixation purposes.

FIG. 48 shows, as another representative embodiment, curvilinear ridges 218, each of which includes a generally linear first end portion 236 and a non-linear, curved (curvilinear) second end portion 238. The distance R₁ between the linear first end portions 236 is greater than the distance R₂ between the curved second end portion 238. In FIG. 48, the curved end portions 236 extend generally inward toward the centerline of the device 200 in a symmetric fashion. Again, it should be appreciated that an asymmetric arrangement of linear and curvilinear portions among the ridges 218 can be used.

In use, as FIG. 49 shows, when the curvilinear ridges 218 nest within the formed linear slots 230, the undulating curved end portions 238 abut against or otherwise extend closer to the walls the formed linear slots 230 than the linear end portions 236. As in FIG. 47, the presence of curvilinear ridges 218 in the arrangement shown in FIG. 49 reduces or prevents “play” or lateral shifting of the device 200 within the formed linear slots 230. The curvilinear ridges 218 also apply and maintain compression between the adjacent bone segments 14 to establish and maintain a desired relationship between them (as shown by arrows in FIG. 49).

FIG. 50 shows another representative embodiment of curvilinear ridges 218. In FIG. 50, the draft of the ridges 218 changes between a vertical draft 240 on the end portions of the ridges 218 (see FIG. 51) to a more horizontal or angular draft 242 on the intermediate portion of the ridges 218 (see FIG. 52). The more horizontal or angular drafts 242 face inward toward the centerline of the device 200, however, the drafts 242 could face in an opposite direction away from the centerline, and in an asymmetric way. As configured in FIG. 50, the distance R₁ between the vertical drafts 240 of the ridges 218 is greater than the distance R₂ between the more horizontal drafts 242 of the ridges.

In use, as FIG. 53 shows, when the curvilinear ridges 218 nest within the formed linear slots 230, the more horizontal drafts 242 abut or otherwise rest closer to the walls the formed linear slots 230 than the vertical drafts 240. As previously described in the context of FIGS. 47 and 49, the presence of different curvilinear ridge drafts 240 and 242 in the arrangement shown in FIG. 53 reduces or prevents lateral “play” or shifting of the device 200 within the formed linear slots 230 due, e.g., to differences in dimensional tolerances among the ridges 218 on the device 200 and slots 230 formed in the bone cavity 222. The curvilinear ridges 218 formed by the different drafts 240 and 242 also apply and maintain compression between the adjacent bone segments to establish and maintain a desired relationship between them (as shown by arrows in FIG. 53).

FIGS. 54 and 55 show anatomic views of a representative placement of the bone fixation/fusion device 200 as previously described. In FIGS. 54 and 55, the device 200 is placed between adjacent bone segments comprising the first and second metatarsal bones and the medial and middle cuneiform bones. In this arrangement, the device 200 also spans portion of the tarsometatarsal joint. The presence of the device 200 serves to fixate these adjacent bone segments and fuse the joint. In FIGS. 54 and 55, the device 200 includes fixation ridges 218 as previously described; however, devices 200 without ridges 218, or with curvilinear ridges, can be used for this purpose as well.

In many cases it is desirable that the device 200 be flexible. It may be desired that the device 200 is flexible about an axis A which extends across the width of the device and is generally parallel to the fracture line or gap between bones to be fused (see FIG. 56). It may also be desired that the device 200 is flexible about an axis B which extends across the length of the device and is generally perpendicular to the fracture line or gap (see FIG. 57). It may also be desirable that the device 200 be flexible about both axes. Various configurations may be used to achieve flexibility.

The device 200 may be formed with a plurality of holes 240 extending through the device. Various hole 240 configurations may be used to achieve the desired flexibility. The holes 240 can extend through the device 200 from the top to the bottom, perpendicular to the top surface as shown in FIG. 58. The holes 240 can extend from the top of the device 200 to the bottom of the device at an angle as shown in FIG. 59. The holes 240 can extend from one side of the device 200 to the opposite side, perpendicular to the surface of the side as shown in FIG. 60. The holes 240 can extend through the device 200 at an angle as shown in FIG. 61.

Alternatively, as shown in FIG. 62, the device 200 can be formed with a hollow cavity 242 to increase the flexibility of the device 200. As shown in FIG. 67, the device 400 can be formed with an accordion-like section 452 to increase the flexibility of the device 400.

As FIG. 64 shows, the bone fixation/fusion device 300 can have a rod-like configuration. In this embodiment, the device 300 includes a central rectangular portion 342 formed with two cylindrical end caps 344. Each cylindrical end cap 344 has a center point 346 (see FIG. 64). The distance between end cap center points 346 is designated as D_(F). The device 300 fits in a slot 222 cut in two bone segments 14 in generally the same manner as is described above. The slot 222 is cut with a cylindrical end aperture 348 at each end of the slot 222. Each cylindrical end aperture 348 has a center point 350 (see FIG. 63). The distance between these aperture center points 350 is designated as D_(S). Desirably, D_(S) at least generally equal to and is not substantially greater than D_(F). In this manner, the distance between the adjacent bone fragments is not enlarged by the presence of the device 300. This is shown in FIG. 65, where D_(S) is approximately equal to D_(F). As shown in FIGS. 63 and 65, the interval G₁ between the adjacent bone segments 14 before installation of the device 300 is the same as after installation of the device 300.

In some instances it may be desirable to make the distance D_(S) between the aperture center points 350 slightly larger than the distance D_(F) between the end cap center points 346. This arrangement is shown in FIG. 66. In this arrangement, when the device 300 is introduced, the cylindrical end caps 344 serve to pull the adjacent bone segments 14 together, while also applying compression to maintain this condition (as shown by arrows in FIG. 66). As FIGS. 63 and 66 show, the interval G₁ between the bone segments before installation of the device 300 is greater than the interval G₂ after installation of the device 300.

The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 

1. A method comprising providing a bone fixation/fusion device comprising a rectangular body and first and second fixation ridges on the body, the first and second fixation ridges being separated by a ridge separation distance, selecting a bone site comprising a first bone segment, a second bone segment, and a non-bony region comprising an interruption between the first and second bone segments, forming a first bone cavity in the first bone segment including forming a first slot sized and configured to receive the first fixation ridge, forming a second bone cavity in the second bone segments across the interruption from the first bone cavity including forming a second slot sized and configured to receive the second fixation ridge, the first and second slots being separated by a slot separation distance that is greater than the ridge separation distance, and inserting the body in the first bone cavity, the second bone cavity, and the interruption with the first and second fixation ridges nesting within the first and second slots, respectively, to apply compression between the first and second bone segments.
 2. A method comprising identifying a bone site comprising a first bone segment, a second bone segment, and a joint between the first and second bone segments, providing a first elongated bone fusion device including an exterior surface treated to provide bony in-growth, providing a second elongated bone fusion device including an exterior surface treated to provide bony in-growth, and fusing the joint by passing the first elongated bone fusion device in a first path through the first bone segment, across the joint, and into second bone segment, passing the second elongated bone fusion device in a second path through the first bone segment, across the joint, and into second bone segment, the first and second paths crisscrossing within the bone segments, the exterior surfaces of the first and second elongated bone fusion device providing bony in-growth within the crisscrossing first and second paths.
 3. A method according to claim 2 further including coupling the first elongated bone fusion device to the second elongated bone fusion device. 